Simulating environmental conditions of a battery pack to test coolant performance

Abstract

Various aspects of this disclosure relate to systems and methods for performing at least one test to simulate at least one environmental condition for at least one battery pack. A controller may: perform a test comprising applying conditions to a battery pack including (i) a plurality of battery cells and (ii) a coolant; receive data from a sensor regarding at least one parameter associated with at least one of the battery pack or the coolant; use the data from the sensor to determine a classification of the coolant used with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Patent Application No. 63 / 558,579, filed February 27, 2024, entitled “Simulating Environmental Conditions on Battery Packs to Test Coolant Performance,” the entire contents of which are incorporated herein by reference. Background Technology

[0002] A battery pack may include a set of battery cells to store electrical energy for use in components coupled thereto. During operation, the battery pack can store additional electrical energy from another source by charging the battery cells. Conversely, the battery pack can supply electrical energy to components by releasing the stored electrical energy from the battery cells. During the charging or discharging operation of the battery cells, the battery pack may experience internal resistance, resulting in heat buildup and temperature increases. Summary of the Invention

[0003] Various aspects of this disclosure relate to a system for performing at least one test to simulate at least one environmental condition of at least one battery pack. The system may include a controller having one or more processors coupled to a memory. The controller may: perform a test including applying conditions to a battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receive data from a sensor regarding at least one parameter associated with at least one of the battery pack or the coolant; use the data from the sensor to determine a classification of the coolant used with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

[0004] In some embodiments, the controller may determine the electrical force to be supplied through the battery pack based on the condition, and perform the test by causing the power source to supply the electrical force through the battery pack according to the condition. In some embodiments, the controller may determine the amount of coolant of the type of coolant to be supplied to the battery pack based on the condition, and perform the test by causing the coolant filler to supply the amount of coolant of the type of coolant to the battery pack according to the condition.

[0005] In some embodiments, the controller may determine, based on the condition, multiple parameters defining at least one vibration supplied by the oscillator to the battery pack, and perform the test by causing the oscillator to supply the at least one vibration to the battery pack according to the multiple parameters of the condition. In some embodiments, the controller may determine whether to perform a second test based on the data regarding the at least one parameter.

[0006] In some embodiments, the controller may determine the classification for approving the use of the coolant with the plurality of battery cells in response to the data regarding the at least one parameter meeting a criterion. In some embodiments, the controller may determine the classification for rejecting the use of the coolant with the plurality of battery cells in response to the data regarding the at least one parameter not meeting a criterion. In some embodiments, the data regarding the at least one parameter may include at least one of the following: (i) the temperature within the battery pack, (ii) the temperature of at least one of the plurality of battery cells, (iii) the temperature of the gas within the battery pack, (iv) the temperature of the coolant, (v) the refractive index of the coolant, (vi) the conductivity, (vii) the hydrogen concentration, (ix) the humidity within the battery pack, and (x) the amount of gas.

[0007] Aspects of this disclosure relate to a method for performing at least one test to simulate at least one environmental condition for at least one battery pack. The method may include: performing the test by a controller, the test including applying conditions to the battery pack, the battery pack comprising (i) a plurality of battery cells and (ii) a coolant; receiving data from a sensor by the controller regarding at least one parameter associated with at least one of the battery pack or the coolant; determining, by the controller, a classification of the coolant used with the plurality of battery cells using the data from the sensor; and providing an output regarding the test by the controller based on the classification of the coolant.

[0008] In some embodiments, the method may include the controller determining, based on the conditions, the electrical force to be supplied through the battery pack. Performing the test may include supplying the electrical force through the battery pack according to the conditions. In some embodiments, the method may include the controller determining, based on the conditions, the amount of coolant of the type of coolant to be supplied to the battery pack. Performing the test may include causing a coolant filler to supply the amount of coolant of the type of coolant to the battery pack according to the conditions.

[0009] In some embodiments, the method may include having the controller determine, based on the condition, multiple parameters defining at least one vibration provided by the oscillator to the battery pack. Performing the test may include having the oscillator provide the at least one vibration to the battery pack according to the multiple parameters of the condition. In some embodiments, the method may include having the controller determine, in response to data regarding the at least one parameter meeting a criterion, a classification approving the use of the coolant with the multiple battery cells. In some embodiments, the method may include having the controller determine, in response to data regarding the at least one parameter not meeting a criterion, a classification rejecting the use of the coolant with the multiple battery cells.

[0010] Various aspects of this disclosure relate to a system for analyzing at least one battery pack. The system may include one or more processors configured to couple with a test environment having a battery pack and sensors. The one or more processors may: perform a test including applying conditions to the battery pack, which includes (i) a plurality of battery cells and (ii) a coolant; receive data from the sensors regarding at least one parameter associated with at least one of the battery pack or the coolant; use the data from the sensors to determine a classification of the coolant used with the plurality of battery cells; and provide an output regarding the test based on the classification of the coolant.

[0011] In some embodiments, the one or more processors may: determine, based on the conditions, the electrical force to be supplied through the battery pack; and perform the test by causing the power supply of the test environment to supply the electrical force through the battery pack according to the conditions. In some embodiments, the one or more processors may: determine, based on the conditions, the amount of the type of coolant to be supplied to the battery pack; and perform the test by causing a coolant filler of the test environment to supply the amount of the type of coolant to the battery pack according to the conditions. In some embodiments, the one or more processors may: determine, based on the conditions, multiple parameters defining at least one vibration supplied to the battery pack by an oscillator of the test environment; and perform the test by causing the oscillator to supply the at least one vibration to the battery pack according to the multiple parameters of the conditions.

[0012] In some embodiments, the one or more processors may determine the classification for approving the use of the coolant with the plurality of battery cells in response to data regarding the at least one parameter meeting a criterion. In some embodiments, the one or more processors may determine the classification for rejecting the use of the coolant with the plurality of battery cells in response to data regarding the at least one parameter not meeting a criterion.

[0013] Numerous specific details are provided to provide a thorough understanding of embodiments of the subject matter of this disclosure. The features described in the subject matter of this disclosure may be combined in any suitable manner in one or more embodiments and / or specific implementations. In this respect, one or more features of one aspect of the invention may be combined with one or more features of different aspects of the invention. Furthermore, it may be recognized in some embodiments and / or specific implementations that additional features may not be present in all embodiments and / or specific implementations. Attached Figure Description

[0014] This disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which like reference numerals denote like elements unless otherwise indicated: Figure 1A block diagram of a system for performing tests to simulate environmental conditions of a battery pack, according to an exemplary implementation, is depicted. Figure 2 A block diagram depicts an environment for simulating various conditions of a battery pack, according to an exemplary implementation scheme; Figure 3 A block diagram of an apparatus for applying oscillations to a battery module to test the performance of the coolant and the battery, according to an exemplary embodiment, is depicted. Figures 4A to 4C A flowchart depicts the process of simulating a battery pack under various conditions according to an exemplary embodiment; and Figure 5 A flowchart is depicted showing a method for performing tests according to an exemplary implementation to simulate environmental conditions of a battery pack. Detailed Implementation

[0015] The following is a more detailed description of various concepts related to methods, apparatuses, and systems for performing tests on coolants under simulated environmental conditions using battery packs, as well as specific implementations of these methods, apparatuses, and systems. The various concepts introduced above and discussed in more detail below can be implemented in any number of ways, as the described concepts are not limited to any particular specific implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0016] A battery pack may include a set of battery cells for storing electrical energy and supplying electrical energy to components coupled to the pack. During operation, the battery pack accepts electrical energy for storage by charging the battery cells. Conversely, the battery pack delivers electrical energy to other components by discharging the battery cells. In both cases, the battery pack may experience increased heat, resulting in higher temperatures. Heat may be generated within the battery cells due to internal resistance and other sources of resistive losses, as well as due to chemical reactions occurring within the battery cells during charging or discharging. Without any cooling mechanism, the battery pack may experience increased heating and eventually thermal runaway events. Such thermal runaway events can cause battery cells to vent and render the battery pack inoperable, causing irreparable damage and shortening the lifespan of the battery cells and the entire battery pack.

[0017] To cool battery cells, a coolant can be supplied to the battery pack to transfer heat and lower the temperature. The coolant selected for supply may have low electrical conductivity (e.g., low electrical conductivity) and high thermal capacity (e.g., the ability to retain heat while maintaining temperature). Regarding electrical conductivity, there may be trade-offs associated with low-conductivity coolants that can be deployed in the battery system. For example, to achieve low conductivity, the additives used in the coolant may be severely limited, where low-conductivity coolants typically provide less robust corrosion protection and have a shorter lifespan.

[0018] Tests can be performed to identify coolants that provide reliable operation while achieving corrosion protection and longer service life. For example, a coolant can be identified as reliable if it can prevent thermal runaway by avoiding resistive heating and hydrogen generation in the battery pack after a coolant leak. The better a coolant's ability to prevent thermal runaway, the more reliable it is considered. One test may include a full battery pack immersion test. In this method, the battery pack is filled with coolant and then kept under observation to determine if any battery venting, thermal runaway, or thermal events occur. However, this test can be destructive and may not allow monitoring of leaked coolant or fluid, as well as any generated gases, during the test. Another test may be a hot wire test. In this method, a lead (e.g., copper wire) is coupled to a power source and then placed in a container containing the coolant to be evaluated. The power source can be switched on for a short period of time, and the conductivity of the coolant can be measured and the appearance of the lead can be observed. However, due to the lack of battery pack inclusion, this test may not be able to test the voltages that the coolant might face. Furthermore, this test may not be able to simulate the gases that might be generated when in contact with the battery cell during a fluid leak.

[0019] To address these and other technical challenges, an apparatus may be provided to allow testing of battery cells during fluid leakage events without generating thermal events. A controller may be configured to couple with this apparatus, sensors, and other components to facilitate the operation of tests on the battery cells. The controller can use sensor data, such as battery cell temperature, hydrogen concentration, and leakage fluid conductivity, to monitor for thermal events. The controller can stop the test before a thermal event occurs to prevent thermal damage to the battery cells or test equipment. This test can be used to formulate and characterize coolants for providing reliable and robust operation in battery systems that are less susceptible to or better prevent resistance heating and hydrogen generation that occur before or partially concurrently with thermal runaway events. The test can also be used to evaluate the configuration and design of battery systems, including the cell chemical composition, orientation, and shape factor regarding thermal runaway parameters in the event of fluid leakage into the battery.

[0020] Now for reference Figure 1This diagram depicts a block diagram of a system 100 for performing tests to simulate environmental conditions of a battery pack. In short, system 100 may include at least one controller 105, at least one test environment 110, and a set of sensors 115A to N (hereinafter collectively referred to as sensors 115), etc. Test environment 110 may include at least one battery pack 120, at least one coolant filler 125 for supplying coolant 180, at least one oscillator 130, and at least one power supply 135, etc. Battery pack 120 may include a set of battery cells 140A to N (hereinafter collectively referred to as battery cells 140) and at least one battery cell mounting device 145 (sometimes referred to herein as a base plate), etc. Controller 105 may include at least one processor 150 and at least one memory 155, etc. Memory 155 may include instructions. Instructions on memory 155 may include at least one test administrator 160, at least one data collector 165, at least one performance evaluator 170, and at least one output processor 175, etc. Controller 105, test environment 110, and the set of sensors 115 may be communicatively coupled to each other.

[0021] Test environment 110 may correspond to or may include a chamber, housing, or room for evaluating the performance of coolant 180 supplied to battery pack 120. Test environment 110 may be used to apply or provide environmental conditions to coolant 180 and battery cells 140 of battery pack 120 to simulate real-world conditions or specific use case scenarios. Test environment 110 may also provide isolation of coolant 180 and battery cells 140 of battery pack 120 from external interference or contamination to maintain the integrity of environmental conditions. Test environment 110 may correspond to the internal volume or space within which various components of system 100 are arranged, positioned, or otherwise configured. Components arranged, positioned, or otherwise configured in test environment 110 may include, for example, a set of sensors 115, battery pack 120 (with battery cells 140), coolant filler 125, oscillator 130, and power supply 135. Test environment 110 may be communicatively coupled to controller 105 to exchange measurement data and command signals.

[0022] Battery pack 120 may correspond to or include a housing for storing, containing, or otherwise including a group of battery cells 140. The housing may define or include an internal volume or area within which the group of battery cells 140 and battery cell mounting equipment 145 are arranged, positioned, or otherwise configured. For example, battery pack 120 may correspond to a closed box for storing a group of battery cells 140 for evaluation. The housing of battery pack 120 may at least partially separate or isolate the group of battery cells 140 from the outside. The housing of battery pack 120 itself may be made of any material, such as electrically insulating materials, including polymers (e.g., polyethylene (PE), polyvinyl chloride (PVC), polytetrafluoroethylene (PTFE), or composite materials (e.g., ceramic, glass, or rubber)). Battery pack 120 may be of any shape, such as prismatic or cylindrical. Battery pack 120 may have any dimensions, such as a height between 3 cm and 5000 cm, a width between 3 cm and 5000 cm, and a length between 5 cm and 2000 cm.

[0023] A group of battery cells 140 may be disposed, located, or otherwise arranged within a battery pack 120. The group of battery cells 140 may at least partially span a volume defined by the housing of the battery pack 120. The group of battery cells 140 may acquire, receive, or otherwise accept electrical energy to be stored and maintained on the battery cells 140. For example, an external power source (e.g., power source 135) may provide power to charge the battery cells 140. The battery cell group 140 may transfer, deliver, or otherwise provide the electrical energy stored thereon to one or more components coupled thereto. The group of battery cells 140 of the battery pack 120 may be configured to be electrically coupled to one or more external components. For example, the battery cells 140 may discharge to provide power to external components.

[0024] Each battery cell 140 can be of any type, such as a lithium-ion battery cell, nickel-zinc battery cell, zinc-bromine battery cell, zinc-cerium battery cell, sodium-sulfur battery cell, or nickel-cadmium battery cell. A group of battery cells 140 can have any shape and size. For example, a battery cell 140 can be prismatic, with a circular, elliptical, rectangular, square, pentagonal, or polygonal base, etc. A battery cell 140 can have a length (or height) ranging from 25 mm to 1000 mm, a width ranging from 25 mm to 1000 mm, and a thickness ranging from 2 mm to 200 mm, etc. Any number (ranging from 1 to 5000) of battery cells 140 can be arranged within the battery pack 120. The battery cells 140 can be in any orientation or direction within the battery pack 120 (e.g., relative to the positive or negative terminal). For example, each battery cell 140 can be arranged such that the positive terminal faces the top of the battery pack 120 and the negative terminal faces the bottom of the battery pack 120, or vice versa. The battery cell 140 can also be arranged, rotated, or oriented in any angular range (e.g., 0 to 360 degrees) about an x-axis, y-axis, or z-axis defined by a horizontal, longitudinal, or vertical plane passing through the battery pack 120.

[0025] The battery cell mounting device 145 may correspond to or define at least one side of the housing of the battery pack 120. For example, the battery cell mounting device 145 may correspond to the bottom lateral side of the housing of the battery pack 120. The battery cell mounting device 145 may support a group of battery cells 140 within the battery pack 120. The group of battery cells 140 may be positioned, arranged, or otherwise arranged along the cell mounting device 145 in the battery pack 120. For example, the group of battery cells 140 may at least partially span the volume defined by the housing of the battery pack 120 along an axis (e.g., a lateral axis) of the cell mounting device 145. The cell mounting device 145 may have any shape and size. The shape of the battery cell mounting device 145 may at least partially correspond to the shape of the battery pack 120. The dimensions of the cell mounting device 145 may at least partially correspond to at least one of the dimensions (e.g., width or length) of the battery pack 120.

[0026] Cell mounting device 145 may be thermally coupled to a group of battery cells 140 within battery pack 120. Cell mounting device 145 may dissipate or transfer heat from within battery pack 120 during operation of the group of battery cells 140, e.g., during charging or discharging. In some embodiments, cell mounting device 145 may be a passive thermal management device for dissipating or transferring heat from the group of battery cells 140 during operation. For example, cell mounting device 145 may be a heat spreader, heat pipe, radiator, heat shield, or insulation. Cell mounting device 145 may transfer heat from the group of battery cells 140 of battery pack 120. In some embodiments, cell mounting device 145 may be an active thermal management device. For example, cell mounting device 145 may include a fan, heat pump, thermoelectric cooler, heat exchanger, or cold plate. Active thermal management devices may be powered by a separate power source.

[0027] The coolant filler 125 can manage, regulate, or otherwise control the supply of coolant 180 to the battery pack 120. The coolant filler 125 can be fluidly coupled to the internal volume of the battery pack 120. The coolant filler 125 may include one or more components for supplying and releasing coolant 180 to and from the battery pack 120. Components of the coolant filler 125 may include, for example: a reservoir for storing coolant 180; at least one pump for drawing coolant 180 from or into the reservoir; an inlet valve for regulating the inflow rate of coolant 180 into the battery pack 120; an outlet valve for regulating the outflow rate of coolant 180 from the battery pack 120; at least one heater (e.g., an electric heater, a cartridge heater, or a heat exchanger) for heating the coolant 180 and controlling the temperature of the coolant when it is supplied to the battery pack 120; at least one nozzle for introducing or adding coolant with specific injection characteristics (e.g., droplet size, injection angle, density, velocity, pattern, and frequency); and one or more manifolds for fluidly coupling the components to each other. The coolant 180 supplied by the coolant filler 125 may be any type of fluid. The coolant 180 may include, for example, a mixture of ethylene glycol (e.g., ethylene glycol, diethylene glycol, or propylene glycol) with water. Coolant 180 can draw or transfer heat energy (or heat) from battery cells 140 in battery pack 120. Coolant filler 125 can be configured to be communicatively coupled to controller 105.

[0028] Oscillator 130 can manage, regulate, or otherwise control the provision of mechanical motion applied to battery pack 120. Mechanical motion may include, for example, movement, rocking, or vibration. Mechanical motion can be applied at any frequency along any number of axes or orientations (e.g., roll, pitch, or yaw). Oscillator 130 may include one or more components for providing mechanical motion to battery pack 120. These components may include, for example, one or more actuators for driving mechanical motion to battery pack 120, support structures, and feedback mechanisms (e.g., control loops) for regulating or stabilizing the mechanical motion provided to battery pack 120. In some embodiments, components of oscillator 130 may include at least one velocity sensor for performing mechanical motion at a specified speed and / or acceleration. The velocity sensor may be coupled to the one or more actuators to alter, adjust, or otherwise modify the velocity or acceleration. One or more components of oscillator 130 may be configured to couple to battery pack 120. For example, actuators may be attached, secured, or otherwise engaged to battery pack 120. The oscillator 130 can be configured to be communicatively coupled to the controller 105.

[0029] Power source 135 can transfer, deliver, or otherwise provide power to a group of battery cells 140 within battery pack 120. Power source 135 may be configured to be electrically coupled to a group of battery cells 140 of battery pack 120. Power source 135 may allow testing of battery pack 120 when battery cells 140 are not fully or substantially charged (e.g., at least 75% of their capacity). Power source 135 may include one or more components for controlling the delivery of power to the battery cells 140 of battery pack 120. These components may include, for example, batteries external to battery cells 140 and power distributors for controlling the power supply to the individual battery cells 140 within battery pack 120. Power source 135 may be configured to be communicatively coupled to controller 105.

[0030] Sensor 115 (sometimes referred to herein as a measuring device or analyzer) measures, acquires, or otherwise obtains data about at least one parameter associated with battery pack 120, battery cell 140, or coolant 180. In some embodiments, at least one sensor 115 may include the capability to preprocess or analyze the acquired data. In some embodiments, sensor 115 may include thermocouples, and these parameters may include, for example, the temperature of each battery cell 140, the temperature of the casing forming battery pack 120, the temperature (e.g., of gases) within battery pack 120, the temperature of at least one battery cell (e.g., the casing of battery cell 140), and the temperature of coolant 180 within battery pack 120. In some embodiments, sensor 115 may include a voltmeter, and this parameter may include the voltage of battery cell 140. In some embodiments, sensor 115 may include an ammeter, and this parameter may include the current of battery cell 140. In some embodiments, sensor 115 may include a power meter, and this parameter may include the power of battery cell 140. The voltmeter, the ammeter, or the wattmeter may be part of or a separate component of the power supply 135.

[0031] In some embodiments, sensor 115 may include a refractometer, and the parameter may include, for example, properties of coolant 180, such as the refractive index of coolant 180. In some embodiments, sensor 115 may include at least one probe (or other instrument), and the parameter may include, for example, properties of coolant 180, including resistivity or conductivity measured via the probe. In some embodiments, sensor 115 may include a gas detector, and the parameter may include the presence, absence, or amount (e.g., concentration) of certain gases (such as hydrogen, carbon monoxide, carbon dioxide, hydrocarbons, and volatile organic compounds, etc.). These gases may include gases formed during testing by the reaction between coolant 180 and battery cell 140. In some embodiments, sensor 115 may include a pressure sensor for measuring, receiving, identifying, or otherwise determining the pressure of gases within battery pack 120. In some embodiments, sensor 115 may include a humidity sensor (e.g., a hygrometer), and the parameter may include, for example, the water content or concentration (or humidity) within the internal volume of battery pack 120. In some embodiments, sensor 115 may include a spectrometer (e.g., Fourier transform infrared spectroscopy (FTIR)), and the parameter may include the type of gas or liquid phase within battery pack 120.

[0032] Sensor 115 may be configured to be coupled to a battery pack 120 or battery cell 140 within a test environment 110. In some embodiments, at least one sensor 115 may be partially located, arranged, or otherwise disposed within the battery pack 120. Sensor 115 may be configured to be coupled to a battery cell 140 of the battery pack 120. In some embodiments, at least one sensor 115 may be located, arranged, or otherwise disposed outside the battery pack 120. Sensor 115 may be configured to be coupled to an internal volume of the battery pack 120. For example, sensor 115 may be coupled via one or more conduits to feed gas from within the battery pack 120. These gases may be carried into a sampling loop that is at least partially recirculated back into the battery pack 120, such that the volume within the battery pack 120 remains closed and isolated from the outside. In some embodiments, these conduits may be configured or equipped with processing equipment (e.g., separators, filters, or demisters) to separate liquids and moisture from gases or liquids within the internal volume of the battery pack 120 (e.g., separating liquid water from water vapor). Each sensor 115 may be configured to be communicatively coupled to the controller 105.

[0033] Controller 105 (sometimes referred to herein as a computing device or computing system) may include at least one computing device or server, which includes one or more processors 150 coupled to memory 155 and software, and is capable of performing the various processes and tasks described herein. For example, controller 105 may combine one or more components in test environment 110, such as sensor 115, coolant filler 125, oscillator 130, or power supply 135, to perform the processes and tasks described herein. Processor 150 may include a microprocessor, application-specific integrated circuit (ASIC), field-programmable gate array (FPGA), or a combination thereof. Memory 155 includes, for example, electronic, optical, magnetic, or any other storage or transfer device capable of providing program instructions to the processor, ASIC, FPGA, etc. The memory may include memory chips, electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), flash memory, or any other suitable memory from which the processor of controller 105 originates. Instructions may include code in any suitable programming language. The memory may include various modules that include instructions configured to be implemented by these processors.

[0034] The test administrator 160, operating on controller 105, can set, configure, or otherwise determine at least one condition to be applied during at least one test of the battery pack 120 using coolant 180. The test may include simulations of environmental factors to mimic real-world operating conditions that the battery cell 140 or coolant 180 will experience. These conditions may specify or limit the test execution of the battery pack 120 to evaluate or analyze the performance of the battery pack 120, battery cell 140, or coolant 180, etc. These conditions may identify, specify, or otherwise include, for example: the type of coolant 180; the amount of coolant 180 to be supplied; the feed rate of coolant 180 to be supplied to battery pack 120; the discharge rate of coolant 180 released from battery pack 120; the amount of voltage, current, or power to battery cell 140; parameters defining the mechanical motion to be supplied to battery pack 120 (e.g., oscillation frequency or force, velocity, and acceleration applied on roll, pitch, or yaw axes); the number of tests to be supplied to battery pack 120; the duration and sequence of tests applied to battery pack 120, etc. These conditions may be set or configured by an operator of controller 105. For example, an operator may use one or more input / output (I / O) devices coupled to controller 105 to set the values ​​of the conditions for tests to be run on battery pack 120. After input, the values ​​of the conditions may be stored and maintained on memory 155, and test administrator 160 may identify the conditions used for testing from the storage on memory 155.

[0035] Test administrator 160 may implement, perform, or otherwise execute tests to impose conditions on battery pack 120 and supply coolant 180 to battery pack 120. When the condition is determined to supply coolant 180 according to specifications, test administrator 160 may perform the test by causing coolant filler 125 to supply coolant 180 according to specified type, amount, or rate, etc. When the condition is determined to supply mechanical movement to battery pack 120, test administrator 160 may perform the test by causing oscillator 130 to perform mechanical movement according to specified parameters or by supplying mechanical movement to battery pack 120. When the condition is determined to supply power to battery cell 140, test administrator 160 may perform the test by causing power supply 135 to supply power to battery cell 140 of battery pack 120 according to specified voltage, current, or power, etc.

[0036] During testing, the test administrator 160 may generate, output, or otherwise produce one or more control signals to be supplied to the coolant filler 125, oscillator 130, or power supply 135, etc., according to the specifications of the conditions. For example, the test administrator 160 may generate a control signal for the coolant filler 125 to supply the quantity of coolant 180 to the battery pack 120 at a specified feed rate. The test administrator 160 may also generate a control signal for the oscillator 130 to apply mechanical motion to the battery pack 120 according to specified parameters. The test administrator 160 may generate a control signal for the power supply 135 to deliver power to a group of battery cells 140 at specified voltage, current, or power, etc. As control signals are generated, the test administrator 160 may transmit, provide, or otherwise send the control signals to the coolant filler 125, oscillator 130, or power supply 135, etc. The control signals may be sent according to the duration and sequence specified by the conditions used for testing.

[0037] By sending a control signal, a test can be performed to impose conditions on the battery pack 120. Upon receiving a control signal from the controller 105, the coolant filler 125 can pump coolant 180 from a coolant reservoir and deliver coolant 180 into the internal volume of the battery pack 120. The coolant filler 125 can supply coolant 180 according to the amount and feed rate specified by the control signal. Furthermore, upon receiving a control signal, the oscillator 130 can translate the specifications of the control signal into commands to actuators to provide mechanical motion to the battery pack 120. The oscillator 130 can provide mechanical motion via one or more actuators to move the battery pack 120 along a horizontal plane (e.g., the x-axis or y-axis) or a vertical plane (e.g., the z-axis) or any combination thereof at a frequency and force specified by the control signal. In some embodiments, the oscillator 130 can perform mechanical motion at a speed or acceleration specified by the control signal via actuators and a speed sensor. This speed and / or acceleration can be along any one or more planes of the battery pack 120 (e.g., the x-axis, y-axis, or z-axis). Furthermore, upon receiving a control signal, power supply 135 can convert the control signal to provide power according to a specified voltage, current, or power, etc. At least partially simultaneously with the test, sensor 115 can acquire or obtain data associated with battery pack 120, battery cell 140, or coolant 180. Sensor 115 can transmit, provide, or otherwise send the acquired data to controller 105.

[0038] Test administrator 160 can apply conditions via coolant filler 125, oscillator 130, or power supply 135, etc., according to the specified duration and sequence of the conditions. Test administrator 160 can maintain a timer to track the elapsed time of the test. Test administrator 160 can compare the timer with the specified duration. When the timer is less than the specified duration, test administrator 160 can determine to continue the test and continue receiving data from sensor 115. Otherwise, when the timer is greater than or equal to the specified duration, test administrator 160 can determine to terminate the test. In some embodiments, test administrator 160 can continue to apply the next test and repeat the functions detailed herein using subsequent tests.

[0039] Data collector 165, operating on controller 105, can retrieve, identify, or otherwise receive data regarding at least one parameter associated with battery pack 120, battery cell 140, or coolant 180 via sensor 115. Data can be received from sensor 115 simultaneously with the operation of testing of battery pack 120. Based on the data received from sensor 115, data collector 165 can determine or identify the value of the at least one parameter. For example, by processing or parsing the data received from sensor 115, data collector 165 can identify: the temperature of each battery cell 140; the temperature (e.g., of gases) within battery pack 120; the temperature of the casing forming battery pack 120; the temperature of coolant 180 within battery pack 120; the voltage of battery cell 140; the current of battery cell 140; the power of battery cell 140; the refractive index of coolant 180; the resistivity or conductivity of coolant 180; the presence, absence, or amount (e.g., concentration) of certain gases (e.g., hydrogen, carbon monoxide, carbon dioxide, hydrocarbons, and volatile organic compounds); measurements of gas pressure within battery pack 120; the water content or concentration (or humidity) within the internal volume of battery pack 120; and the identification of the type of gaseous or liquid phase within battery pack 120, etc. Data collector 165 can store and maintain the data (or parameter values) on memory 155 of controller 105.

[0040] A performance evaluator 170, executed on controller 105, may use data received from one or more sensors 115 to identify or determine at least one classification for the use of coolant 180 with a group of battery cells 140 in battery pack 120. This classification may define, specify, or otherwise identify whether coolant 180 is accepted (or approved) or rejected for use with a group of battery cells 140 in battery pack 120. To determine this classification, performance evaluator 170 may examine or compare the data regarding the one or more parameters with one or more criteria. The criteria may specify, define, or otherwise identify a threshold for each corresponding parameter, according to which coolant 180 is identified as accepted or rejected. For example, the criteria may specify that the temperature of coolant 180 within battery pack 120 must not exceed 75°C to 95°C, and that the hydrogen concentration of the gas forming within the casing of battery pack 120 must not exceed 7% to 33% of the lower explosive limit (LEL) of the gas, etc. In some implementations, the standard may specify, define, or otherwise identify a threshold rate of change (e.g., the rate of hydrogen accumulation or temperature rise) or a range of acceptable values ​​for a given type of parameter.

[0041] For each parameter of the data, the performance evaluator 170 can compare the value of that parameter with each threshold of the corresponding parameter identified by a standard. If the value of the data does not meet (e.g., greater than or equal to) the threshold of at least one of the parameters, the performance evaluator 170 can classify the coolant 180 as unapproved, restricted, or rejected for use with a group of battery cells 140. If the value of the data meets (e.g., less than) the threshold of the parameter, the performance evaluator 170 can determine that the data meets the standard. Furthermore, the performance evaluator 170 can identify or determine that the coolant 180 is approved, permitted, or otherwise accepted for use with a group of battery cells 140. In some embodiments, when the value of the data meets the threshold of one type of parameter, the performance evaluator 170 can continue to compare the values ​​of other types of parameters with the corresponding thresholds of the standard. When the value from the data meets all the thresholds of the parameters specified by the standard, the performance evaluator 170 can classify the coolant 180 as acceptable for use with a group of battery cells 140. After determining the classification, the performance evaluator 170 can store and maintain the classification on memory 155 using one or more data structures (e.g., arrays, tables, matrices, trees, heaps, or linked lists). The performance evaluator 170 can identify conditions under which coolant 180 is identified as acceptable or unacceptable for use with a group of battery cells 140 in battery pack 120.

[0042] In some implementations, the performance evaluator 170 may identify or determine whether to continue another test based on data received from one or more sensors 115. In some implementations, a set of tests may be provided to the battery pack 120, and each test may correspond to an evaluation or analysis of at least one parameter. To determine whether to continue, the performance evaluator 170 may compare the value of the parameter with a threshold for each corresponding parameter identified by a standard. If the value of the data does not meet (e.g., is greater than or equal to) a threshold for at least one parameter, the performance evaluator 170 may determine to stop or terminate the testing of the battery pack 120. On the other hand, if the value of the data meets (e.g., is less than) a threshold for a given parameter, the performance evaluator 170 determines to continue the next test of the battery pack 120. The performance evaluator 170 may provide instructions to the test administrator 160 to identify the next condition for testing.

[0043] Output processing program 175, executing on controller 105, may generate, produce, or otherwise provide at least one output for testing based on the classification of coolant 180. The output may include information identifying the classification of coolant 180 as acceptable or unacceptable for use with a group of battery cells 140. When the classification identifies coolant 180 as acceptable for use with a group of battery cells 140, output processor 175 may generate output indicating that coolant 180 is acceptable for use with a group of battery cells 140. Otherwise, when the classification identifies coolant 180 as unacceptable for use with a group of battery cells 140, output processor 175 may generate output indicating that coolant 180 is unacceptable for use with a group of battery cells 140. In some embodiments, output processing program 175 may include information identifying the conditions used for testing in the output. After the output is generated, output processing program 175 may provide the output for presentation. For example, output processor 175 may generate, render, display, and / or otherwise present the classification of coolant 180 and information about test conditions on a display coupled to controller 105.

[0044] In this way, the entire system 100 facilitates the identification of the coolant 180 used in conjunction with the battery cells 140 and power electronics. Furthermore, based on data from the sensor 115, the controller 105 can identify or determine the conditions under which the coolant 180 is suitable or capable of operating with a group of battery cells 140. Compared to other methods for testing the performance of the coolant 180, the tests managed by the controller 105 and provided to the battery pack 120 can be used to evaluate low-conductivity coolants with increased corrosion protection and longer lifespan. The selected coolant 180 can be deployed in battery packs for various applications, such as electric vehicles or battery storage, to achieve reliable performance with enhanced corrosion protection and longer lifespan.

[0045] Now for reference Figure 2 This diagram depicts a system or environment 200 for simulating various conditions of a battery pack. Environment 200 may include one or more components of system 100 as detailed herein. Environment 200 may include at least one isolation zone 205 to isolate the components therein from the outside. Environment 200 may include at least one simulated battery pack 210 within the isolation zone 205. The simulated battery pack 210 may be designed to simulate the environment of at least one battery cell 215 in several ways.

[0046] The simulated battery pack 210 can be a clean, enclosed environment. The simulated battery pack 210 is completely isolated from the ambient atmosphere. The simulated battery pack 210 can be designed to contain and seal various fluids (e.g., coolant) and gases (e.g., gases formed by the interaction of the coolant with the battery cells). The simulated battery pack 210 can be constructed using a non-conductive material, such as high-density polyethylene (HDPE). This material is resistant to various fluids, including mixtures of ethylene glycol and water. During testing, the ethylene glycol-water coolant may not leach substances from the HDPE material. If ions leach from the simulated battery pack 210 into the test fluid, the conductivity of the coolant may be affected. In this test, the conductivity of the liquid coolant can be controlled to mitigate temperature rise due to resistance heating and hydrogen production due to electrolysis.

[0047] Fluids (e.g., coolant fluid) can be added to the simulated battery pack 210 via coolant filler 225. In addition to liquids, the simulated battery pack 210 may contain gases, but venting (using a pressure relief valve or similar) may occur if the pressure inside the simulated battery pack 210 exceeds 0.3 psig (pounds per square inch gauge pressure), potentially leading to test failure. Gases may be generated during testing or during battery thermal runaway. By containing gases within the simulated battery pack 210, any gases generated during testing can be measured. This venting strategy can contribute to the integrity and overall design and construction of the simulated battery pack 210. The battery pack can be configured as a pressure vessel designed to withstand moderate pressures (e.g., 10 psig to 20 psig).

[0048] The simulated battery pack 210 can hold a variety of battery cells 215. The battery cells 215 can be held in place on the battery mounting device 220 (e.g., by clamps) to prevent them from moving during vibration or movement of the test apparatus or floating in the test coolant during testing. Battery cells 215 of any chemical composition (e.g., prismatic, cylindrical, pouch, or button cell) can be evaluated in the simulated battery pack 210. The orientation of the battery cells 215 (e.g., orientation relative to the cathode or anode) can be configured or set within the simulated battery pack 210. For example, the battery cells 215 can be arranged with the anode facing the top of the simulated battery pack 210 and the cathode facing the bottom of the simulated battery pack 210, and vice versa. The battery cells 215 can be oriented in any angular range (e.g., 0 degrees to 360 degrees) about an x-axis, y-axis, or z-axis defined through the sides of the simulated battery pack 210. The simulated battery pack 210 can be used to evaluate the relationship between the thermal runaway behavior of the battery cell 215 or the battery pack 210 and factors such as factors, type and chemical composition.

[0049] Environment 200 may include at least one power source 230 (e.g., 1000V, 10amp), which can be deployed to reproduce various battery pack voltages without relying on fully charged battery cells 215. Power source 230 may be electrically coupled to battery cells 215 via one or more power lines 240. The 1000V power source 230 allows battery cells 215 to operate at full battery pack voltage without relying on the large amount of energy stored on battery cells 215. Using power source 230 instead of a full battery pack improves the reliability of the simulated battery pack 210. Tests run in this simulated battery pack 210 may be destructive to battery cells 215. Using power source 230 instead of a full battery pack to run tests allows for the consumption of fewer battery cells instead of many (e.g., 1 battery cell instead of 500 to 1000 battery cells). This allows testing to be scaled up to any number of battery cells for a variety of applications, such as for electric vehicles. Power source 230 can be coupled to distribution box 235 to distribute or supply power to a group of battery cells 215 within analog battery pack 210.

[0050] Various components within environment 200 can be controlled by control devices. These control devices can be used in combination to operate sensors, analyzers, and other test controls. For example, the control devices can operate remote coolant addition devices and automated test shutdown procedures. Environment 200 may also include a linear oscillation device capable of generating linear oscillations up to 60 cycles per minute to provide dynamic elements for testing. A large vibration table can be used in this device to provide this capability. Tests conducted using a specific device have shown that an oscillation rate of 20 cycles per minute is sufficient to simulate fluid motion during vehicle drive cycles.

[0051] The simulated battery pack 210 may use electrically insulating materials (e.g., HDPE or polycarbonate) and may include various ports (e.g., ports 250 and 255) for instrumentation and sampling. Ports 250 and 255 may be configured to separate liquids and moisture from the liquids inside the simulated battery pack 210. This allows for accurate and reliable measurement of the concentration of hydrogen (H2) relative to other gases within the battery pack 210. The simulated battery pack 210 and battery cell 215 may be equipped with several measuring devices, such as a refractometer 245 and a gas analyzer. A range of temperature measuring devices (e.g., thermocouples) may be used to measure the temperature of battery cell 215, the temperature of air and gases within the simulated battery pack 210, and the temperature of any liquids added to the simulated battery pack 210, etc. Furthermore, the distribution box 235 may be equipped with shunts for measuring the current and voltage of battery cell 215 or the circuitry.

[0052] Refractometer 245 measures the properties of the coolant fluid in the simulated battery pack 210 during testing. Refractometer 245 can be fluidly coupled to the simulated battery pack 210 to ensure that the coolant fluid circulates through refractometer 245 itself to provide accurate measurements. A conductivity sensor can be used to measure the conductivity of the fluid in the simulated battery pack 210 during testing. Initially, the conductivity of the coolant can be set by the substance of the coolant itself plus the content of any additives within the liquid coolant. Changes in conductivity can be caused by the chemical reaction of the coolant additives with the energized battery system. During testing, conductivity can be correlated with physical processes related to battery thermal events, such as electrolysis and the reaction of coolant additives with electrical components. Reactions involving coolant additives can be evaluated by interpreting data from sensors (including refractometer 245, gas sensing devices, pressure sensors, and temperature sensors), analyzing the coolant, or performing hardware checks after testing.

[0053] Devices for hydrogen measurement (e.g., sensors or chromatographs) can be deployed to measure hydrogen that may be generated during testing from electrolysis or battery cell exhaust. Similar devices can be used to measure carbon monoxide, carbon dioxide, and total hydrocarbons generated during testing. These gases can be generated by the chemical reaction of a coolant at elevated temperatures or conductivity during battery cell exhaust, thermal runaway, or combustion of any fluid in the test environment. Gas sample flow rates for gas analysis and sensor measurements can range from less than 50 mL / min to 150 mL / min, and sensors can perform measurements every 30 seconds to 10 minutes. Humidity sensors can be deployed to measure the water content in the atmosphere inside the simulated battery pack 210. Pressure sensors can be arranged to measure the pressure of gases within the simulated battery pack 120 to detect potential problems (e.g., malfunctions or breakage) in the gas seal of the simulated battery pack 120 during simulation and testing. Other measuring devices (e.g., spectrometers for Fourier transform infrared (FTIR) spectroscopy) can be deployed to measure various types of gases in the gas or liquid phase within the simulated battery pack 210. The gas measuring device may be included in a sampling loop that recirculates to the analog battery pack 210, keeping the entire isolation zone 205 closed.

[0054] The simulated battery pack 210 may have other features such as pressure relief valves, electrical insulation properties of materials, and power supply usage. Battery cells 215 may be placed in a thermally contained chamber capable of containing a fire or explosion associated with battery thermal runaway. Electrically insulating material (e.g., silicone or rubber) may be placed between battery cells 215 and the thermally contained chamber to prevent electric shock. Electrically insulating material may also be placed around the simulated battery pack 210 to protect technicians operating the device from electric shock.

[0055] Furthermore, sensors (e.g., gas sensors and thermometers) can be used to determine when to continue or terminate testing in the simulated battery pack 210. For example, testing can be stopped if termination conditions occur in the test environment, such as when the hydrogen concentration in the air within the simulated battery pack 210 reaches 7% to 33% of the lower explosive limit (LEL), when the temperature of the outer casing of the battery cell 215 exceeds 75°C to 90°C, or when a flame is detected within the simulated battery pack 210. Additionally, testing can also be stopped when a malfunction of any one or more sensors is detected.

[0056] Now for reference Figure 3A block diagram depicts an apparatus 300 for applying oscillations to a battery module to test coolant and battery performance. The apparatus 300 may include at least one controller 305, at least one simulated battery pack 310, and at least one oscillator 315. The controller 305 may be coupled to various components and the simulated battery pack 310 to facilitate the operation of the test. The simulated battery pack 310 may be an enclosed box containing any number of battery cells 320A to N (hereinafter collectively referred to as battery cells 320). The simulated battery pack 310 may contain fluids and gases.

[0057] The simulated battery pack 310 may include one or more ports 340A to N (collectively referred to as ports 340) for adding fluid to and / or draining fluid from the simulated battery pack 310. Ports 340 may also be used to return the test environment to initial conditions and to extract a portion of the coolant for sampling and analysis. Fluid may be introduced into the simulated battery pack 310 via ports 340 for testing. In some embodiments, ports 340 may be coupled to separate liquid or gas types (e.g., separating water from moisture). Fittings may include one or more pipes (e.g., conduits or channels) and processing equipment (e.g., dryers, membranes, or filters). This separation can be used to accurately measure various quantities (e.g., quantity, concentration, or pressure) of gases within the simulated battery pack 310. In some embodiments, fittings coupled to ports 340 may be configured to couple to at least one pump (e.g., a circulation pump) to guide or remove at least a portion of liquid or gas from the interior of the simulated battery pack 310 for measurement. For example, the pump can evacuate a predetermined vacuum (e.g., 2.0 bar vacuum) onto a pipeline carrying sample gas from the simulated battery pack. The pressurized sample gas can then pass through a pressure reducing valve. This valve can pass the gas to a pressure reducer or bypass to recirculate the gas back into the simulated battery pack 310. The sample gas passing through the pressure reducing valve can flow into a water separator and then into a gas chromatograph-mass spectrometer for analysis of the gas within the simulated battery pack 310.

[0058] The controller 305 acquires data (e.g., resistance heating and electrolysis) via a series of sensors 335A to N (collectively referred to as sensors 335) to determine whether a fluid is suitable for use in a battery system. Sensors 335 can measure various data, such as the coolant level 330 within the simulated battery pack 310, measurements of temperature (T) or pressure (P), identification and determination of gases (e.g., hydrogen (H2), water (H2O), and oxygen (O2)) within the volume of the simulated battery pack 310, water volume, and the conductivity (σ) of the coolant. The simulated battery pack 310 can be designed to vent in cases of increased or excessive pressure within the simulated battery pack 310 (e.g., when the pressure exceeds 0.3 psig). The simulated battery pack 310 can be equipped with various measuring devices. The measuring devices and actions are controlled using the controller 305. Several different features and engineering controls can be used for the enclosure and experimental environment. The simulated battery pack 310 can be placed on an oscillator 315 (e.g., a shaking table or vibration table) capable of providing linear oscillations.

[0059] In this way, the test environment, together with the controller, can perform various processes (e.g., tests) to simulate real-world conditions, thereby evaluating and assessing the coolant's performance under various operating scenarios. This comprehensive testing can be used to evaluate whether the battery pack and coolant can withstand different environmental conditions. By monitoring parameters using sensors, various data about the battery pack, such as temperature, composition, concentration, pressure, and / or conductivity, can be obtained. During test execution, the data can be used to automatically detect potential adverse events (e.g., thermal runaway) and stop the test before damaging the battery cells or battery pack. This data can be used to identify any problems and make changes to the configuration and design of the battery cells and battery pack, as well as the selection of coolant for the battery system.

[0060] For example, controllers and test environments can be used to evaluate battery storage systems or battery pack design and coolant selection for electric vehicles (EVs). Test environments can be used to test different coolant and battery pack configurations to simulate real-world conditions (e.g., the driving environment of an EV), including charging, discharging, and / or mechanical vibration. Controllers manage the operation of battery pack tests by applying electricity, supplying coolant, simulating mechanical vibration, and introducing other stresses that the battery pack might face under such conditions. Combined, a series of sensors continuously monitor parameters from the battery pack, such as temperature, hydrogen concentration, and conductivity.

[0061] Based on the collected parameters or information, the controller can evaluate the performance of the coolant to classify it as suitable or unsuitable for use with the battery pack according to criteria. The criteria can specify a range of values ​​for each corresponding parameter, and the coolant is determined to be suitable or unsuitable according to that range. If the coolant is classified as unsuitable, it can be excluded from use with the battery pack. Conversely, if the coolant is classified as suitable by the controller, it can be selected for use with the battery pack. Using the selected coolant, the battery pack can be deployed for use with that coolant (e.g., incorporated or added as part of a battery storage system or electric vehicle). The selected coolant should be less susceptible to the effects of resistive heating and hydrogen generation that occur before or partially simultaneously with a thermal runaway event, or better able to prevent such resistive heating and hydrogen generation. Overall, this comprehensive testing method provides a robust framework for evaluating the performance of coolants and battery packs under various environmental conditions.

[0062] Now for reference Figures 4A to 4C The flowchart depicts a process 400 simulating various conditions of a battery pack. Process 400 can be performed or implemented using any of the components described herein, such as combining... Figures 1 to 3 The components described in detail. From Figure 4A At the start of process 400, the test apparatus can be prepared by cleaning, drying, connecting wiring, and starting the emission equipment (402). A simulated battery pack can be assembled (e.g., by placing battery cells within the volume of the simulated battery pack) (404). A controller connected to the simulated battery pack can begin data collection (406). The controller can identify a coolant sample (408).

[0063] The controller can set the fluid level to high or low (410). When the fluid level is set to low, the controller can cause the coolant filler to add pre-conditioned coolant to the battery pack to a low fluid level (e.g., 1 gallon to 5 gallons) (412). Otherwise, when the fluid level is set to high, the controller can cause the coolant filler to add pre-conditioned coolant to a high fluid level (e.g., at 5 gallons to 20 gallons) (414). The controller can also set the power level to low or high (416). When the power level is set to high, the controller can cause the power supply to provide a high level of voltage (e.g., 300V to 500V) (418). Otherwise, when the power level is set to low, the controller can cause the power supply to provide a low level of voltage (e.g., 50V to 150V) (420).

[0064] Go to Figure 4BThe controller can determine whether to perform a dynamic test (430). When it is determined that a dynamic test should be performed, the controller can cause the oscillator to provide mechanical motion to the battery pack (432). Conversely, when it is determined that a dynamic test should not be performed, the controller can prevent the oscillator from providing mechanical motion to the battery pack (434). The controller can use one or more sensors to monitor test data (436). The controller can determine whether the hydrogen concentration exceeds a threshold concentration (e.g., 7% to 33% of the lower explosive limit (LEL)) (438). If the hydrogen concentration does not exceed the threshold concentration, the controller can determine whether to continue the test (440). The controller can determine whether the system temperature exceeds a threshold temperature (e.g., 75°C to 95°C) (442). If the system temperature does not exceed the threshold temperature, the controller can determine whether to continue the test (444). The controller can determine whether the test time has exceeded the test time limit (e.g., 5 minutes to 60 minutes) (446). If the test time has not exceeded the time limit, the controller can determine whether to continue the test (448) and can continue to monitor test data and repeat from step (436).

[0065] Continue to Figure 4C When the hydrogen concentration exceeds a concentration threshold, the controller can determine whether to terminate the test (460). When the system temperature exceeds a threshold temperature, the controller can determine whether to terminate the test (462). When the test time has exceeded the time limit, the controller can determine whether to terminate the test (464). The controller can determine whether the rate of hydrogen accumulation or temperature rise exceeds the limits of the battery system (466). If the rate of hydrogen accumulation or temperature rise exceeds an acceptable limit, the controller can determine to refuse the use of coolant with the battery cell (468). In contrast, if the rate of hydrogen accumulation and temperature rise does not exceed an acceptable limit, the controller can determine to accept the use of coolant with the battery cell (470).

[0066] Now for reference Figure 5 The document depicts a flowchart of a method 500 for performing tests to simulate environmental conditions of a battery pack. Method 500 can be performed or implemented using any of the components described herein, such as in combination with... Figures 1 to 3 The components described in detail. In a brief overview of method 500, the controller may determine test conditions (505). The controller may perform tests based on these conditions (510). The controller may receive data from the tests (515). The controller may determine whether the data meets one or more criteria (520). If the data meets the criteria, the controller may determine a classification for accepting the use of coolant (525). Otherwise, if the data does not meet the criteria, the controller may determine a classification for rejecting the use of coolant (530). The controller may provide output based on the classification (535).

[0067] More specifically, the controller (e.g., controller 105 or 305) may identify or determine the test conditions (505) to be applied to at least one battery pack. These test conditions may identify or define various specifications of the tests to be performed on the battery pack according to them. These test conditions may include, for example: the type of coolant; the amount of coolant to be supplied; the coolant feed rate; the coolant discharge rate; the amount of voltage, current, or power to the battery cells; parameters defining mechanical motion; the number of tests; the duration and sequence of applying the tests to the battery pack; combinations thereof; and other possible conditions.

[0068] The controller may perform, implement, or otherwise execute at least one process (e.g., at least one test) based on these conditions (510). During the execution of the test, the controller may transmit, provide, or otherwise send one or more control signals. These control signals may be applied to various components in the test environment to perform these test conditions. These components may include oscillators, coolant fillers, or power supplies, etc. In some embodiments, the controller may send control signals for the coolant filler to provide that amount of coolant to the battery pack at a specified feed rate. In some embodiments, the controller may generate control signals for the oscillator to apply mechanical motion to the battery pack according to specified parameters. In some embodiments, the controller may generate control signals for the power supply to deliver power to the battery cells in the battery pack according to specified voltage, current, or power, etc.

[0069] The controller may retrieve, identify, or otherwise receive data (515) during the execution of at least one process (e.g., the test). During test execution, the controller may acquire, collect, or receive data from one or more sensors regarding at least one parameter associated with the battery pack. This data may include, for example: the temperature of each battery cell; the temperature of the gas within the battery pack; the temperature of the casing forming the battery pack; the temperature of the coolant; the voltage of the battery cells; the current of the battery cells; the power of the battery cells; the refractive index of the coolant; the resistivity or conductivity of the coolant; the presence, absence, or amount (e.g., concentration) of certain gases (e.g., hydrogen, carbon monoxide, carbon dioxide, hydrocarbons, and volatile organic compounds); measurements of the pressure of the gas within the battery pack; the water content or concentration (or humidity) within the battery pack; and identification of the type of gaseous or liquid phase within the battery pack, etc.

[0070] The controller can identify or determine whether the data meets one or more criteria (520). The criteria can specify or limit the value range of a parameter of the data, according to which the coolant will be determined to be acceptable or unacceptable for use with the battery pack. For each parameter of the collected data, the controller can compare the parameter value with the value range of the corresponding criterion. When the value of a parameter from the data is within the value range of the corresponding criterion, the controller can determine that the data meets the criterion. If the data meets the criterion, the controller can identify or determine a classification for accepting the use of the coolant (525). Based on the classification, the coolant can be incorporated or included for use with the battery pack.

[0071] In contrast, when the value of at least one parameter from the data is outside the range of the corresponding standard, the controller can determine that the data does not meet the standard. Otherwise, if the data does not meet the standard, the controller can identify or determine a category for rejecting the use of the coolant (530). Based on the category, the coolant can be excluded from use with the battery pack. The controller can send, transmit, or otherwise provide an output (535) based on the category. This output can identify or indicate the coolant's category. In some embodiments, the output can identify or include data about one or more parameters. The controller can provide this output for presentation via a display.

[0072] For the purposes of this disclosure, the term "coupled" refers to two components being directly or indirectly engaged or connected to each other. This engagement can be fixed or movable in nature. For example, the "coupled" driveshaft of an engine to a transmission indicates a movable coupling. This engagement can be achieved using two components or two components and any additional intermediate components. For example, the communicative "coupled" connection of circuit A to circuit B could mean that circuit A communicates directly with circuit B (i.e., without intermediaries) or indirectly with circuit B (e.g., through one or more intermediaries).

[0073] While various circuits with specific functions are shown in the accompanying drawings, it should be understood that components may include any number of circuits for performing the functions described herein. For example, the activities and functions of the circuitry of controller 105 may be combined in multiple circuits or as a single circuit. Additional circuitry with additional functions may also be included. Furthermore, the controller may control other activities beyond the scope of this disclosure.

[0074] As mentioned above, and in one configuration, a “circuit” can be implemented in a machine-readable medium for execution by various types of processors. An identified circuit of executable code may, for example, comprise one or more physical or logical blocks of computer instructions, which may be organized, for example, into objects, procedures, or functions. However, the executable code of the identified circuit does not need to be physically placed together, but may include different instructions stored in different locations that, when logically connected, constitute the circuit and achieve its intended purpose. In practice, a circuit of computer-readable program code can be a single instruction or multiple instructions, and can even be distributed across several different code segments, different programs, and several memory devices. Similarly, operational data may be identified and exemplified within the circuit herein, and can be embodied in any suitable form and organized within any suitable type of data structure. Operational data may be collected as a single dataset, or may be distributed across different locations including different storage devices, and may exist at least partially as electronic signals on a system or network.

[0075] While the term "processor" has been briefly defined above, the terms "processor" and "processing circuitry" are intended to be interpreted broadly. In this regard, and as mentioned above, a "processor" can be implemented as one or more general-purpose processors, application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), or other suitable electronic data processing components configured to execute instructions provided by memory. The one or more processors can take the form of a single-core processor, a multi-core processor (e.g., a dual-core processor, a triple-core processor, a quad-core processor, etc.), a microprocessor, etc. In some embodiments, the one or more processors can be located externally to the device; for example, the one or more processors can be remote processors (e.g., cloud-based processors). Alternatively or additionally, the one or more processors can be internal to the device and / or local. In this regard, a given circuitry or its components can be locally located (e.g., as part of a local server, a local computing system, etc.) or remotely located (e.g., as part of a remote server, such as a cloud-based server). Therefore, a "circuitry" as described herein can include components distributed across one or more locations.

[0076] Although the illustrations herein may show a specific order and composition of method steps, the order of these steps may differ from the depicted order. For example, two or more steps may be performed simultaneously or partially simultaneously. Furthermore, some method steps may be combined as discrete steps, steps performed as combined steps may be divided into discrete steps, the order of certain processes may be reversed or otherwise changed, and the nature or number of discrete processes may be altered or varied. According to alternative embodiments, the order or sequence of any element or device may be changed or substituted. All such modifications are intended to be included within the scope of this disclosure as defined by the appended claims. Such variations will depend on the machine-readable medium and hardware system chosen, as well as the designer's choice. All such variations are within the scope of this disclosure.

[0077] The foregoing description of the embodiments has been presented for purposes of illustration and description. This foregoing description is not intended to be exhaustive or to limit this disclosure to the precise forms disclosed, and modifications and variations may be made in accordance with the foregoing teachings, or may be obtained from this disclosure. The embodiments were chosen and described to explain the principles of this disclosure and its practical application, enabling those skilled in the art to utilize various embodiments and with various modifications suitable for the intended particular use. Other substitutions, modifications, alterations, and omissions may be made in the design, operating conditions, and arrangement of the embodiments without departing from the scope of this disclosure as set forth in the appended claims.

[0078] Therefore, this disclosure may be embodied in other specific forms without departing from the spirit or essential characteristics of this disclosure. The described embodiments should be considered in all respects as illustrative only and not limiting. Therefore, the scope of this disclosure is indicated by the appended claims rather than by the foregoing description. All variations within the meaning and scope of equivalents of the claims are included within the scope of the claims.

Claims

1. A system for performing at least one test to simulate at least one environmental condition for at least one battery pack, the system comprising: A controller having one or more processors coupled to a memory, the controller being configured to: Perform a test, the test including applying conditions to the battery pack, the battery pack comprising (i) a plurality of battery cells and (ii) a coolant; Receive data from the sensor regarding at least one parameter associated with at least one of the battery pack or the coolant; The data from the sensor is used to determine the classification of the coolant used with the plurality of battery cells; as well as The classification based on the coolant provides output regarding the test.

2. The system of claim 1, wherein the controller is further configured to: Determine the electrical power to be provided by the battery pack based on the aforementioned conditions; and The test is performed by supplying electrical power through the battery pack according to the conditions.

3. The system according to claim 1, wherein the controller is further configured to: Based on the conditions, determine the type and amount of coolant to be supplied to the battery pack; and The test is performed by having a coolant filler supply the battery pack with the amount of the coolant of the coolant type according to the conditions.

4. The system of claim 1, wherein the controller is further configured to: Based on the conditions, determine multiple parameters defining at least one vibration supplied by the oscillator to the battery pack; and The test is performed by having the oscillator provide at least one vibration to the battery pack according to the plurality of parameters of the conditions.

5. The system of claim 1, wherein the controller is further configured to determine whether to perform a second test based on the data regarding the at least one parameter.

6. The system of claim 1, wherein the controller is further configured to determine the classification for approving the use of the coolant with the plurality of battery cells in response to data satisfying the criteria for the at least one parameter.

7. The system of claim 1, wherein the controller is further configured to determine, in response to data regarding the at least one parameter not meeting a criterion, the classification of rejecting the use of the coolant with the plurality of battery cells.

8. The system of claim 1, wherein the data relating to the at least one parameter includes at least one of the following: (i) the temperature within the battery pack, (ii) the temperature of at least one of the plurality of battery cells, (iii) the temperature of the gas within the battery pack, (iv) the temperature of the coolant, (v) the refractive index of the coolant, (vi) the conductivity, (vii) the hydrogen concentration, (ix) the humidity within the battery pack, and (x) the amount of gas.

9. A method for performing at least one test to simulate at least one environmental condition of at least one battery pack, the method comprising: The test is performed by the controller and includes applying conditions to the battery pack, which includes (i) a plurality of battery cells and (ii) a coolant; The controller receives data from sensors regarding at least one parameter associated with at least one of the battery pack or the coolant; The controller, using the data from the sensors, determines the classification of the coolant used with the plurality of battery cells; as well as The controller provides output regarding the test based on the classification of the coolant.

10. The method according to claim 9, further comprising: The controller determines the electrical force to be supplied by the battery pack based on the conditions. and Performing the test also includes supplying electrical power through the battery pack according to the conditions.

11. The method according to claim 9, further comprising: The controller determines the amount of coolant of the type of coolant to be supplied to the battery pack based on the conditions; and Performing the test also includes supplying the coolant filler to the battery pack in the amount of the coolant of the coolant type, according to the conditions.

12. The method according to claim 9, further comprising: The controller determines, based on the conditions, multiple parameters defining at least one vibration to be provided by the oscillator to the battery pack; and Performing the test also includes causing the oscillator to provide the battery pack with at least one vibration according to the plurality of parameters of the conditions.

13. The method of claim 9, further comprising determining, by the controller and in response to the data regarding the at least one parameter satisfying a criterion, the classification for approving the use of the coolant with the plurality of battery cells.

14. The method of claim 9, further comprising determining, by the controller and in response to data regarding the at least one parameter not meeting a criterion, the classification of rejecting the use of the coolant with the plurality of battery cells.

15. A system for analyzing at least one battery pack, the system comprising: One or more processors configured to couple with a test environment having a battery pack and sensors, the one or more processors being configured to: Perform a test, the test including applying conditions to the battery pack, the battery pack comprising (i) a plurality of battery cells and (ii) a coolant; Receive data from the sensor regarding at least one parameter associated with at least one of the battery pack or the coolant; The data from the sensor is used to determine the classification of the coolant used with the plurality of battery cells; as well as The classification based on the coolant provides output regarding the test.

16. The system of claim 15, wherein the one or more processors are further configured to: Determine the electrical power to be provided by the battery pack based on the aforementioned conditions; and The test is performed by supplying electrical power to the battery pack through the power source of the test environment according to the conditions.

17. The system of claim 15, wherein the one or more processors are further configured to: Based on the conditions, determine the type and amount of coolant to be supplied to the battery pack; and The test is performed by supplying the battery pack with the amount of the coolant of the type specified by the coolant filler in the test environment, according to the conditions.

18. The system of claim 15, wherein the one or more processors are further configured to: Determine the conditions identifying multiple parameters, which define at least one vibration provided to the battery pack by an oscillator in the test environment; and The test is performed by having the oscillator provide at least one vibration to the battery pack according to the plurality of parameters of the conditions.

19. The system of claim 15, wherein the one or more processors are further configured to determine the classification for approving the use of the coolant with the plurality of battery cells in response to data satisfying the criteria for the at least one parameter.

20. The system of claim 15, wherein the one or more processors are further configured to determine, in response to data regarding the at least one parameter not meeting a criterion, the classification of rejecting the use of the coolant with the plurality of battery cells.

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